Probe station having multiple enclosures

ABSTRACT

A probe station for probing a test device has a chuck element for supporting the test device. An electrically conductive outer shield enclosure at least partially encloses such chuck element to provide EMI shielding therefor. An electrically conductive inner shield enclosure is interposed between and insulated from the outer shield enclosure and the chuck element, and at least partially encloses the chuck element.

This application is a continuation of application Ser. No. 09/451,698,filed Nov. 30, 1999, now U.S. Pat. No. 6,288,557 which is a continuationof application Ser. No. 08/870,335, filed Jun. 6, 1997, now U.S. Pat.No. 6,002,263.

BACKGROUND OF THE INVENTION

The present invention relates to probe stations, commonly known aspackage or wafer probers, used manually, semiautomatically or fullyautomatically to test semiconductor devices. More particularly, theinvention relates to such probe stations having EMI shielded enclosuresfor substantially enclosing the test devices, such as those probestations shown in commonly-owned U.S. Pat. Nos. 5,266,889 and 5,457,398which are hereby incorporated by reference.

The probe stations shown in the foregoing patents are capable ofperforming both low-current and high-frequency measurements within asingle shielded enclosure. However, as electrical test currentsdecrease, or as electrical test frequencies increase, the use of merelya single EMI shielding enclosure becomes less adequate. In the mostsensitive of measurements, and particularly (although not necessarily)when guarding is employed for low current measurements as described inU.S. Pat. No. 5,457,398, the choice of the shield potential is critical.Reflecting such criticality, the single shield enclosures shown in theforegoing patents have in the past been equipped with selectiveconnectors enabling the shield potential to match that of themeasurement instrumentation ground while being isolated from otherconnectors, or alternatively to be biased by another connector, or to beconnected to AC earth ground. Usually the measurement instrumentationground is preferred since it provides a “quiet” shield ideally having noelectrical noise relative to the measurement instrument. However, if theshielding enclosure is exposed to EMI (such as electrostatic noisecurrents from its external environment), its ideal “quiet” condition isnot achieved, resulting in unwanted spurious currents in the chuckassembly guard element and/or the supporting element for the testdevice. The effect of such currents is particularly harmful to theoperation of the guard element, where the spurious currents result inguard potential errors causing leakage currents and resultant signalerrors in the chuck element which supports the test device.

For high-frequency measurements, guarding is typically not employed.However, for the most sensitive of measurements, the “quietness” of theshield is still critical. For this reason, it is common practice toconstruct a fully shielded room, commonly known as a screen room, largeenough to contain a probe station with its own separate shieldenclosure, test equipment, and several operators. However, screen roomstake up a large amount of space, are expensive to build, and areineffective with respect to noise sources within the room.

The environmental influences which ordinarily compromise the desiredquiet condition of a shield are the motion of external objects atconstant potential which cause spurious shield currents due to varyingcapacitance, and external AC voltages which cause spurious shieldcurrents via constant capacitance. For sensitive measurements, what isneeded is a truly quiet shield unaffected by such environmentalinfluences.

Also, to reduce the need for a screen room, and provide a shieldunaffected by closely adjacent environmental influences, such quietshield structure should be compact.

BRIEF SUMMARY OF THE INVENTION

The present invention satisfies the foregoing need by providing a probestation having respective inner and outer conductive shield enclosuresinsulated from each other, both enclosures at least partially enclosingthe chuck assembly element which supports the test device, and also itsassociated guard element if one is provided. The outer shield enclosure,which is preferably connected either directly or indirectly to AC earthground, intercepts the external environmental noise, minimizing itseffects on the inner shield and on the chuck assembly elements enclosedby the inner shield.

Such inner and outer shield enclosures are preferably built integrallyinto the probe station and therefore are compact.

The foregoing and other objectives, features, and advantages of theinvention will be more readily understood upon consideration of thefollowing detailed description, taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of an exemplary probe station in accordance withthe present invention, with the top of the station partially removed toshow interior structure.

FIG. 2 is a partially sectional, partially schematic view taken alongline 2—2 of FIG. 1.

FIG. 3 is a partially sectional, partially schematic view taken alongline 3—3 of FIG. 1.

FIG. 4 is an enlarged sectional view of a portion of a flexible wallelement of the embodiment of FIG. 1.

FIG. 5 is a partial top view of an alternative embodiment of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

An exemplary embodiment of a probe station in accordance with thepresent invention, indicated generally as 10 in the figures, has anelectrically conductive outer enclosure 12 including a conductiveraisable hinged lid 12 a electrically connected thereto. A chuckassembly 14 for supporting a test device is laterally positionable by achuck positioner assembly having orthogonally arranged lateral X-axisand Y-axis positioners. A lateral X-axis positioner 16 has a laterallyextending positioning screw (not shown) driven by an electric motor 18.The X-axis positioner 16 is partially enclosed by a conductive housing16 a, and optionally also by flexible pleated rubber boots 16 b foraccommodating positioning movements while preventing the entry andescape of dirt particles. The conductive housing 16 a is insulated fromthe outer enclosure 12 by respective dielectric anodized coatings onboth the exterior of the housing 16 a and the interior of the enclosure12, and is indirectly connected electrically to AC earth ground by meansof conventional motor cabling and a grounded motor power supply (notshown), represented schematically in FIG. 2 by a high-impedanceelectrical path 22. The X-axis positioner 16 selectively moves a Y-axispositioner 24, oriented perpendicularly to the X-axis positioner 16,along the X-axis.

The lateral Y-axis positioner 24 is constructed similarly to the X-axispositioner 16, and includes an outer conductive housing 24 a withoptional flexible pleated rubber boots 24 b. The conductive housing 24 ais electrically connected to the housing 16 a of the X-axis positioner.The motor 26 of the Y-axis positioner 24 extends through a horizontalslot 28 (FIG. 3) in the side of the enclosure 12, thereby permitting itto be moved freely along the X-axis by the X-axis positioner 16.Alternatively, a larger enclosure 12 could eliminate the slot 28.

A conventional Z-axis positioner 30, having a conductive housing 30 aelectrically connected to the housing 24 a, is movable along the Y-axisby the Y-axis positioner 24. The Z-axis positioner 30 includesrespective internal electric motors (not shown) which selectivelyreciprocate a plunger assembly 30 b vertically and rotate it through alimited range about a vertical axis in a known manner.

The outer conductive enclosure 12 is connected by a low-impedance path32 (FIG. 2) directly to AC ground. Collectively, the outer enclosure 12,12 a and the positioner housings 16 a, 24 a, and 30 a cooperate toprovide an electrically conductive outer shield enclosure whichseparates the remainder of the probe station from environmental noisesources, whether located externally of the enclosure 12 or internallythereof inside the positioner housings. Such noise sources include theelectric motors 18 and 26, and those motors within the Z-axis positioner30, as well as other electrical components such as cables, thermalheaters, encoders, switches, sensors, etc.

Mounted atop the plunger assembly 30 b and electrically insulatedtherefrom by dielectric spacers 34 is a square-shaped conductive chuckshield 36 having a downwardly depending conductive cylindrical skirt 36a. Mounted atop the chuck shield 36 and electrically insulated therefromby dielectric spacers 38 is a conductive chuck guard element 40, whichincludes a peripheral cylindrical conductive guard skirt 40 a. The guardskirt 40 a peripherally surrounds a conductive chuck element 42 inspaced relation thereto. The chuck element 42 is insulated from theguard element 40 and guard skirt 40 a by dielectric spacers 44 and has asupporting surface 42 a thereon for supporting a test device duringprobing. Probes (not shown) are mounted on a probe ring 46, or othersuitable type of probe holder, for contacting the test device when theZ-axis positioner 30 raises the supporting surface 42 a upwardly intoprobing position.

As shown schematically in FIG. 2, the chuck shield 36 is electricallyconnected to the shield of a triaxial cable 37 interconnected with themeasurement instrumentation. The guard element 40, together with theguard skirt 40 a, is connected to the guard conductor of the triaxialcable, and the chuck element 42 is connected to the center or signalconductor of the triaxial cable 37. Preferably a further guard elementin the form of a conductive plate 48, also electrically connected to theguard conductor of the triaxial cable and insulated from the remainderof the probe station by dielectric spacers 50, is suspended in opposedrelationship to the supporting surface 42 a. The conductive plate 48also provides a connection to a guard element on the bottom of a probecard (not shown). Further details of the electrical connections, and ofthe dielectric spacers utilized to insulate the chuck elements from eachother, are explained in U.S. Pat. No. 5,457,398 which is incorporatedherein by reference. As explained in such patent, the connections to thechuck elements 40 and 42 cause such elements to have substantially equalpotentials to minimize leakage currents there between.

An electrically conductive inner shield enclosure 52, which alsopreferably acts as the probe station's environment control enclosure notonly for purposes of EMI shielding but also for purposes of maintaininga dry and/or dark environment, is mounted by dielectric spacers 54 tothe interior of the outer enclosure 12 so as to be interposed betweenand insulated from the outer enclosure 12 and the chuck elements 40 and42. Like the chuck shield 36, the enclosure 52 is connected to theshield of the triaxial cable 37 associated with the measurementinstrumentation. A selective connector mechanism, schematicallyillustrated as a three-way switch 56 in FIG. 2, enables respectivedifferent potentials to be selectively established on the enclosure 52.Normally the selective mechanism 56 would be in the “float” positionwhereby the potential of the enclosure 52 depends on the triaxial shieldassociated with the measurement instrumentation. However the enclosure52 can alternatively be electrically biased by the selective connectormechanism 56, or interconnected with the outer enclosure 12 if desiredfor particular applications. In the normal situation where the innerenclosure 52 is not electrically connected to the outer enclosure 12,the outer shield components 12, 12 a, 16 a, 24 a, and 30 a protect theinner shield 52 from external noise sources, so that the inner shield inturn can minimize noise-induced spurious currents affecting the chuckelements 40 and/or 42 and thereby maximize the accuracy of the testmeasurements.

Movement of the chuck assembly 14 laterally by the X-axis and Y-axispositioners 16 and 24, respectively, is accomplished with the Z-axispositioner retracted in order to position the test device with respectto the probe or probes. During such movement, the environmentalintegrity of the inner enclosure 52 is maintained by means of anelectrically conductive flexible wall assembly indicated generally as58. The wall assembly 58 includes a pair of flexibly extensible andretractable pleated wall elements 58 a which are extensible andretractable along the X-axis, and a further pair of such wall elements58 b which are flexibly extensible and retractable along the Y-axis. Theoutermost ends of the wall elements 58 a are electrically connected tothe inner surfaces of the inner enclosure 52 by screws (not shown). Theinnermost ends of the wall elements 58 a are similarly connected to arectangular metal frame 60 supported by the Y-axis positioner housing 24a by means of brackets 62 (FIG. 3) and dielectric spacers 64 whichinsulate the frame 60 from the Y-axis positioner housing 24 a. Theoutermost ends of the flexible wall elements 58 b, on the other hand,are electrically connected to the inner surfaces of the ends of theframe 60 by screws (not shown), while their innermost ends are similarlyconnected to respective conductive bars 66 insulatively supported bydielectric brackets 68 atop the Z-axis positioner housing 30 a.Conductive plates 70 are electrically connected to the bars 66 andsurround the chuck shield skirt 36 a in spaced relation thereto.

As the X-axis positioner 16 moves the Y-axis positioner 24 and chuckassembly along the X-axis, it likewise moves the frame 60 and itsenclosed wall elements 58 b along the X-axis as the wall elements 58 aextend and retract. Conversely, as the Y-axis positioner 24 moves theZ-axis positioner and chuck assembly along the Y-axis, the wall elements58 b similarly extend and retract along the Y-axis.

With reference to FIG. 4, a cross-section of an exemplary pleat 72 ofthe flexible wall elements 58 a and 58 b is shown. The electricallyconductive core 74 of the pleated material is a fine mesh polyester,chemically coated with copper and nickel. The core 74 is sandwichedbetween respective layers 76 which are nylon fabric with a PVCstiffener. The respective layers 76 in turn are covered by respectiveouter layers 78 of polyurethane. The pleated material is preferablyfluid-impervious and opaque so that the inner enclosure 52 can serve asa dry and/or dark environment control chamber, as well as an EMI shield.However, if the inner enclosure 52 were merely intended to serve as ashield, the pleated material need not be fluid-impervious or opaque.Conversely, if the inner enclosure 52 were intended to serve merely asan environment control chamber for dry and/or dark purposes, without EMIshielding, the pleated material's conductive core 74 could beeliminated. Also, alternative pleated materials of other compositions,such as thin, highly flexible stainless steel or other all-metal sheetmaterial, could be used.

As a further alternative, a one-piece flexible wall assembly 80 (FIG. 5)having circular or oblate curved rings of pleats 82 surrounding thechuck assembly 14 could be provided in place of the wall assembly 58 topermit flexible extension and retraction in radial X and Y directions.The outer extremity of the wall assembly 80 is electrically connected bya curved conductive frame 84 to the inner shield enclosure 52. The innerextremity of the wall assembly 80 is supported by a circular conductivering 86, and an underlying circular dielectric bracket (not shown)comparable to bracket 68, upon the Z-axis positioner housing 30 a.

As a further alternative, the inner enclosure 52 could utilizeconductive or nonconductive sliding plates, such as those shown in U.S.Pat. No. 5,457,398 incorporated herein by reference, in place of theflexible wall assembly 58 if the more desirable characteristics of theflexible wall assembly are not needed. As a still further alternative,unpleated flexibly extensible and retractable material could be usedinstead of pleated material in the wall assembly 58.

The terms and expressions which have been employed in the foregoingspecification are used therein as terms of description and not oflimitation, and there is no intention, in the use of such terms andexpressions, of excluding equivalents of the features shown anddescribed or portions thereof, it being recognized that the scope of theinvention is defined and limited only by the claims which follow.

What is claimed is:
 1. A probe station for probing a test device, saidprobe station comprising: (a) a chuck assembly having a chuck assemblyelement with a supporting surface for supporting said test device duringprobing thereof; (b) an electrically conductive outer enclosure at leastpartially enclosing said supporting surface and insulated therefrom; (c)an electrically conductive inner enclosure interposed between andinsulated from said enclosure and said supporting surface, and at leastpartially enclosing said supporting surface; (d) respective electricalconductors connected to said supporting surface and said innerenclosure, respectively, causing said inner enclosure and saidsupporting surface to have respective potentials independent of eachother; and (e) a selective connector,either interconnecting or,alternatively, disconnecting said inner enclosure and said outerenclosure electrically with respect to each other.